Air conditioning condenser — removal and installation
Warning: The air conditioning system is under high pressure. Do not loosen any hose fittings or remove any components until the system has been discharged. Air conditioning refrigerant should be properly discharged into an EPA-approved recovery/recycling unit by a dealer service department or an automotive air conditioning repair facility. Always wear eye protection when disconnecting air conditioning system fittings.
Warning: Wait until the engine is completely cool before beginning this procedure.
Caution: The receiver/drier should be replaced whenever the air conditioning condenser is replaced (see Troubleshooting).
1. Have the refrigerant discharged by an automotive air conditioning technician.
2. Disconnect the cable from the negative battery terminal, then remove the battery hold-down clamp (see Engine electrical systems).
3. Remove the front bumper cover (see Body) and the headlight housings (see Chassis electrical system).
4. Drain the cooling system (see Tune-up and routine maintenance).
5. Remove the hood latch, then detach the hood release cable from the clips along the radiator support (see Body).
6. Disengage the radiator air deflector clips and remove the air deflector from the top of the radiator.
7. Disconnect the electrical connectors to the horns (see Chassis electrical system), then remove the front bumper upper support reinforcement bolts and remove the support along with the horns as an assembly.
8. Disconnect the inlet and outlet line bolts to the condenser (see illustration). Cap the open fittings immediately to keep moisture and dirt out of the system.
i. 8 Condenser inlet and outlet line bolt locations
9. Detach the water by pass pipe from the fan shroud.
10. Remove the fan shroud support mounting bolts and separate the support from the top of the fan shroud.
11. Carefully lift the air conditioning con- denser up and out making sure not to damage the cooling fins on the condenser or the radiator as the condenser is lifted out.
12. Install the condenser to the fan shroud, making sure the rubber cushions fit on the mounting points properly.
13. Reconnect the refrigerant lines, using new 0-rings where needed.
14. If a new condenser is installed, add 1.35 ounces (40 cc) of refrigerant oil to the condenser before installing it.
15. Reinstall the remaining parts in the reverse order of removal. Have the system evacuated, charged and leak tested by the shop that discharged it.